Category: bourbon

Jack Daniel’s Distillery Visit

This spring I toured eight American whisky distilleries, including Jack Daniel's.

As you'd expect, Jack Daniel's is a huge operation with a very slick tour. You start with a video at the visitors' center, then take a shuttle up to the top of the hill. There, they burn sugar maple wood into charcoal for the Lincoln County Process, in which newly-distilled spirit is filtered through charcaol before barrel aging. They weren't burning wood on the day I visited, so no bonfire for me.

Then we visited the cave spring where they get the water to ferment the grains before distilling, and then into Jack's old office. We saw the safe that killed Jack Daniel – he kicked it out of frustration one day and the injury caught gangrene and it eventually killed him.

The mashbill for Jack Daniel's is 80% corn, 8% rye, and 12% malted barley. The corn is #1 yellow corn. They say with a higher corn amount, you need a higher malted barley amount to help ferment it. They have 56 fermentation vats on-site that hold 40,000 gallons apiece. Fermentation lasts for 6 days – quite a long time. It reaches 11-12 percent alcohol after fermentation.

There are four distillation columns, all made of copper, and needing to be replaced every 9 or 10 years. (The whisky is only distilled in one of them, not all four. They just have four because they make so much whiskey.) Unlike most bourbon, there is no second distillation in a "thumper" or "doubler." They distill the whisky up to 140 proof (160 is the legal limit).

Then the whiskey goes through the Lincoln County Process. There are 72 vats, each filled with a ten foot layer of sugar maple charcoal. The whiskey is sprayed on the top of the vats and it slowly drips down through the charcoal, taking about 4-6 days to get all the way through. The charcoal in each vat is replaced every 4-5 months.

This is in contrast to George Dickel, the other major Tennessee whiskey, where they fill the vats up with charcoal and spirit, let it sit a week, and then drain the whole thing.

They say the charcoal filtering removes 80 percent of hte oils and impurities from the distillate. Gentleman Jack is filtered through charcoal a second time at bottling, through a thinner layer of charcoal.

The whiskey is aged in their 81 warehouses spread throughout the region. Barrels are "quarter-sawn American oak" with a #4 char. It takes one 60 year-old tree to make one barrel. On the plus side, there is extra wood left over from the tree for other things, and many barrels are reused after aging American whiskey to age other spirits for more than 60 years apiece.

The barrels are first toasted and then charred at their own cooperage, the Brown-Forman Cooperage.

Last year they sold 10.23 million cases of Jack.

Master Distiller Jeff Arnett describes the taste of Jack as "Sweet and oakey," as opposed to the "bold and spicy" of other American whiskies. We tasted Jack before it goes through the Lincoln County Process – it was noticeably oilier and grainier than it is afterward. Arnett says that the Lincoln County Process "removes the bitterness associated with the grain bill."

The Jack Daniel's Single Barrel bottlings always come from the top (hottest, most wood-influenced) floors of the rickhouse, while the Green Label comes from the ground floor.

Visiting Jack Daniel's

Contrary to popular belief, there are some tours where you're allowed to taste whiskey at Jack Daniel's. Those cost $10.

Though they don't really sell whiskey at the gift shop, they do sell "commemorative bottles" full of whiskey.

Visitor information is on the website here.

June 15, 2012
Distillery Visit: George Dickel

This spring I visited the George Dickel distillery, located in Cascade Hollow, Tennessee.

Dickel and Jack Daniel's are the two defining Tennessee whiskies: both employ the "Lincoln County Process" of running the new spirit through 10+ feet of charcoal before it is aged. Contrary to popular belief, this is not a requirement of Tennessee whisky, as Tennessee whisky is not its own category by US law. By putting "Tennessee" on the label it must be made in Tennessee, but beyond that Dickel and Daniel's meet all the requirements for bourbon.

In 1870, George Dickel founded the distillery, originally called Cascade Whisky, and it was renamed by his wife after Dickel died. Prohibition came early to Tennessee, so in 1911 the distillery moved to Kentucky, then closed during national Prohibition. Twenty years after Prohibition the distillery was rebuilt about half a mile from its original location.

The mashbill for Dickel bourbon is 84% corn, 8% rye, and 8% malted barley. All bourbon uses a majority of corn, malted barley to aid in fermentation, and a minority of either wheat or rye. At Dickel it is a pretty high percentage of corn for a sweeter tasting whiskey.

Most of the corn used for George Dickel is local, and the rye and barley comes from North Dakota. They distill here four days each week currently, so they have the capacity to make a lot more bourbon than they currently do.

The grains, which are cooked to make them easier to ferment, ferment with yeast for three or four days before they are distilled. The still is 42 inches in diameter and is three storeys tall. In a column still, the fermented mash (the grain solids and the liquids, unlike in scotch whisky where only the liquids are distilled) goes in near the top of the column. During distillation the alcohol comes out the top of the still and everything else goes out the bottom.

Most bourbons (but not Jack Daniel's) undergo a second distillation in either a "thumper" or "doubler." This second distillation acts like a pot still, so they say. Doublers are more common, and used here at George Dickel.

Originally Dickel distilled whiskey in the winter as they said it tasted best then. To mock that, the newly-distilled whisky is chilled to 40 degrees Fahrenheit before it is added to vats of sugar maple charcoal for the Lincoln County Process.

While at Jack Daniel's the whiskey is continuously dripped through a huge vat of charcoal and collected at the bottom, at Dickel the chilled distillate fills up the tank with the charcoal and sits together for about a week before it is drained. They have to refill the charcoal in each vat every 12-18 months.

The first distillation reaches 115 proof. The second distillation brings it up to 135 proof (160 is the legal limit). Though they can put whiskey in the barrel at up to 125 proof, at Dickel they store it at 115. The whiskey is aged in new American oak barrels with a char #4 on the staves and char #2 on the barrel heads.

As is common in American whiskey, the barrel warehouses (rickhouses) are not located right at the distillery, but are scattered about the hilltops nearby. This way they can take advantage of the cooling winds that blow through. Dickel has about 150,000 barrels of whiskey aging today.

Dickels rickhouses are all one storey structures. (Four Roses also uses one storey rickhouses but six storeys is the norm.) With one storey warehouses, there is less temperature differential between barrels aging at the top of the warehouse (those will be the hottest and get the most wood influence the fastest) and the bottom of the warehouse (where whiskey ages relatively slowly).

The angel's share, the amount of alcohol that evaporates from the barrels during storage, is 5 percent the first year and 3 percent each year after.

After aging, the whiskey is run though a paper filter to remove any charcoal bits before bottling.

Visiting George Dickel

Last year 17,000 visitors came through the distillery. The tour is free, but unfortunately there is no whiskey tasting as part of it. Visitors can buy bottles but can't drink them on site. For more information, visit Dickel.com.

June 8, 2012
Summer Whisky Cocktails in Whisky Advocate Magazine
Holy Smokes! They put my story on Summer Whisky Cocktails on the cover of Whisky Advocate Magazine!

Inside it's 7 pages of deliciousness, with recipes brought to you by:
- Alan Akwai
- Brendan Dorr
- Jon Santer
- David Delaney, Jr.
- Larry Rice
- Sam Ross
- Kevin Diedrich
- Kevin Kelpe
- Mike Ryan
There are swizzles and punches and highballs and bucks and smoky drinks! Run screaming to your local newsstand and pick up the Summer 2012 issue of Whisky Advocate today!
June 6, 2012
Four Roses Bourbon Distillery Visit

This week I was in Kentucky for a quick visit to the Four Roses distillery. For some history on this brand, see this post a I wrote a few years ago. In short, Four Roses was only a bourbon in Japan for many years, and has recently come back to the US market. They use two mashbills (grain makeup) and five strains of yeast to make ten recipes of bourbon.

The ten recipes blended together ensure a consistent bourbon from batch to batch. Another way they help do this is by having single-story rickhouses. While other brands have several floors in their rickhouses with quite extreme temperature variations in them, at Four Roses they're only one floor high, six barrels tall, with a much less variation in temperature from top to bottom.

We did two tastings at the distillery. One was tasting all ten recipes of the white dog. They have quite the wide range of flavor, from fruity to spicy. The second was tasting several barrels all with the same recipe from different barrels. This was fascinating as there was a surprisingly large difference: one tasted like oloroso sherry, one like apricot socks, one like creamed corn.

Largely because they've been selling mostly in Japan, they use all non-GMO corn. Distillery Jim Rutledge says they don't really advertise that because he doesn't expect they'll be able to get enough non-GMO corn to continue doing so: everything is being replaced by the modified stuff.

Well I have to run to another event- more on this interesting brand another time.

December 8, 2010
Turkey Cocktail

In my latest post on FineCooking.com, I tell the tale of a recent Thanksgiving tradition: drinking Wild Turkey.

I also link to my experiments with Wild Tofurkey and share a new-fangled Old Fashioned recipe from the brand.

Check it out here.

November 22, 2010
Home Bar Recommendations: One of Each

When Jonny Raglin and Jeff Hollinger were looking to open Comstock Saloon (hopefully this month), they had a big limitation to work with: the size of the back bar. It only has room for one or two types of each base spirit. This is a challenge for Raglin in particular as between his former post as Bar Manager at Absinthe and his consultant gig at Dosa on Fillmore he was working with probably 30 different types of gin alone.

This inspired a story I wrote for the April edition of 7×7 magazine. I also spoke with Martin Cate of Forbidden Island who had the luxury of choosing over 200 rums for the bar, but that didn't leave room for much else. Before opening he sent out an email requesting advice on one of each tequila (blanco, reposado, anejo) for the bar. I also spoke with Marcovaldo Dionysos, who was very selective when choosing the bottles for Clock Bar. He said he had to balance familiar brands that consumers know with less-recognized spirits he'd prefer to work with.

In the story I asked each of Raglin, Cate, and Dionysos to pick one of
each- vodka, tequila, rum, whisky, and gin- that would work the best in
the most cocktails, while also being good enough for sipping. The
results should point home mixologists who may also not have room for 30 brands of gin toward the one bottle to buy.

The Ultimate Five-Bottle Bar, Perfect for Apartment Dwelling

by Camper English

What happens when the city’s top bartenders are forced to choose? Introducing the ultimate five-bottle bar, perfectly sized for apartment dwelling.

Click the link above to read the story. In the print edition there are also recommendations for one each of sweet and dry vermouth and an orange liqueur/triple sec.

April 1, 2010
Maker’s Mark Distillery Visit

As part of a visit to the Kentucky Bourbon Festival, I visited the Jim Beam and Maker's Mark distilleries in September. Today I'll talk about visiting Maker's Mark.

The distillery has been around since 1805, but was purchased by Mr. Samuels, founder of Maker's Mark, in the early 1950's. This distillery will receive 70,000 visitors this year, and not just because they're fans of the product- this is one of the most beautiful distilleries I've ever seen. With its little bridges, common color theme, trees, and lawns it's more like a college campus. In fact when I was there in September the tours going through almost looked like summer tours for prospective students.

Maker's is different than other bourbons as it is 70% corn (all non-GMO) plus malted barley and "soft red winter wheat" instead of the rye in most other brands. Also pretty unique is that at this distillery they make only one bourbon- only one product at all.

Also at the distillery, they use an "anaerobic processor" to capture methane biogass
from their waste, which allows them to reduce their natural gas use by
15-30 percent. They also sell off their spent grains for animal feed,
but I'm not sure at what point that happens.

One thing I learned about Kentucky bourbon is that the products produced here are tied to the distiller who produced them (or popularized them), rather than the company. When people talk about a bourbon, they're talking about a distiller, and not usually the current one. When you talk about Jim Beam and the Small Batch Bourbon collection, people think about Booker Noe, who recently died, not so much Fred Noe who is the current voice of the company. When Fred Noe talks about the line, he talks about his father, not himself.

That was also the case at Maker's Mark- Master Distiller Kevin Smith said that his job is to keep Maker's Mark the same as Bill Samuels Sr. created it, and if they created a new product then it wouldn't be a brand extension, it would probably be something new. When they do special editions of Maker's with a different color of wax on the bottle, it's still the same whisky inside.

Anyway, I think it's interesting how different companies with a history are loyal to the company philosophy or the founder or the product itself.

Maker's rotates their barrels in the warehouse, and is the only bourbon distillery to still rotate all of the inventory. The barrels are first put at the top of the warehouse for three years, then spend another three at the bottom.

Beyond its flavor, Maker's is known for its branding- the iconic bottle with the red dripping wax unique to each bottle. The bottle design, wax seal, and the "maker's mark" itself were created by Mrs. Samuels, Bill Samuels' wife. The dripping wax is actually trademarked, which is why you don't see other brands doing it.

Those are all of my fun facts for now. More pictures from my Maker's Mark distillery visit are here.

October 9, 2008
A visit to the Jim Beam distillery

In September I visited the Jim Beam and Maker's Mark distilleries as part of the Kentucky Bourbon Festival. For all the distilleries I've been to in 10 different countries, I'd never seen a bourbon distillery.

The Claremont Jim Beam distillery is a huge facility, and one of two where the product is distilled. They receive tons of grain daily, and distill whiskey 24 hours a day, 6 days each week. The annual output is around 6 million cases of bourbon each year. (I believe they also distill the small batch bourbon collection here- Booker's, Baker's, Knob Creek, and Basil Hayden.) Beam uses 70 warehouses to store their 1.7-1.8 million barrels of bourbon that are aging.

Beam is made from corn, rye, and barley. Interestingly, we get GMO corn in the US bourbon, but they distill, age, and bottle non-GMO spirit separately for export to Europe where they have restrictions against GMO products. (I definitely want to learn more about this so if anyone has a non-hysterical GMO book/video they can recommend let me know.)

The bourbon is first column distilled in the "beer still" that's about six stories high. It is then distilled a second time in the "doubler" which they say looks like a pot still but is continuous. (We didn't see it.)

The barrel warehouses are not only enormous, they're very tall- nine stories, with each story holding three tiers of barrels. At the top of the warehouse where it's hot, the barrels gain proof over time as more water evaporates out of the barrel (through the wood) than spirit. At the bottom of the warehouse, the whiskey loses proof as more alcohol evaporates than water.

When selecting barrels to use for Beam, they take barrels from each level of the warehouse to make up the final blend. For the Booker's bottling, which is cask-strength and unfiltered, they only take barrels from one middle floor.

After aging, the barrels are emptied, diluted, and bottled. You can find more pictures on my Flickr page here. In tomorrow's post, I'll talk about the bottling facility- with videos!

October 7, 2008